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HOME > PRODUCTS > IMPROVED-CONCRETE
| Improved-Concrete Installation Instructions |
 Track Preparation
- Track structure should be constructed per the surface data sheet.
- For best results, use new ballast, ties, and rail.
- Ties should be of good quality and in the same plane. Ties that are twisted or not set flat must be adzed or replaced.
- Ties must be placed center-to-center (c-c) as follows:
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| Panel Length |
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Timber Tie |
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Concrete Tie |
| 9-foot |
18" c-c |
18" c-c |
| 10-foot |
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24" c-c |
| 12-foot |
18" c-c |
24" c-c |
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- Rails should be welded. Grind welds smooth to avoid interfering with panels.
- Make certain track gauge is 56 1/2".
- Sweep the ties and rail to remove ballast and debris which may interfere with seating of the panels.
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Installation Steps
- If ordered, gauge abrasion pads should be centered on the ties, field abrasion pads should be placed even with the outer edge of the ties. For timber ties, fasten the abrasion pads to the ties with the nails provided with the order. For concrete ties, abrasion pads must be glued in place.
- Begin at the center of the crossing and place the rubber RailGuard field and gauge panels against the rail.
- Lubricate the rubber RailGuard with soapy water or pipe slick prior to installing concrete panels.
- Install the first concrete gauge panel at the center of the crossing. Concrete gauge panels should be centered on the ties and fit tight against the rubber. Continue to lubricate the rubber panels and apply top-down pressure to push the concrete in place. Do not hammer or beat upon the concrete panel.
- Install remaining gauge panels.
- During placement of concrete panels, it may be necessary to apply pressure to RailGuard panels to keep joints tight and ends on ties. Jack or push panels with boom tip or backhoe.
- Follow the same steps to install concrete field panels. Push concrete panels against RailGuard panels for a tight fit against the rail. Make sure panel ends are centered on ties.
- Install end-restraints. The restraints are designed to span both the rubber RailGuard and concrete panels. Use the three-inch lags provided to fasten the end-restraints to the ties. If the RailGuard panels extend beyond the concrete panels, jack the RailGuard even with the concrete.
- For lagged installation, predrill the wood ties with a 1/2" drill bit and install 3/4" timber screws using a torx bit and impact wrench. Apply pressure to hold field panels tight against the rail while drilling and fastening. For welded installation, tack weld the gauge panels with three 3-inch skip welds and field panels with two 3-inch skip welds.
- If end deflectors have been ordered, tack weld the deflectors to the end restraints and to the top edge of the concrete panel's metal frame.
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